Peugeot 405 Manual

Exhaust system - general information, removal and refitting
Fuel/exhaust systems - carburettor models / Exhaust system - general information, removal and refitting


General information
1 The exhaust system sections are joined by flanged joints or clamped cone joints. Except on TU engines the manifold to downpipe joint is of the spring-loaded ball type, to allow for movement in the exhaust system. On TU engines the spring-loaded joint is located at the rear of the front pipe. On early models earth straps are fitted between the underbody and the exhaust system (see illustration).

16.1 Exhaust-to-floor panel earth strap fitted to early models
16.1 Exhaust-to-floor panel earth strap fitted to early models

2 The system is suspended throughout its entire length by rubber mountings.

Removal
3 Each exhaust section can be removed individually, or alternatively, the complete system can be removed as a unit. Even if only one part of the system needs attention, it is often easier to remove the whole system and separate the sections on the bench.

4 To remove the system or part of the system, first jack up the front or rear of the car and support it on axle stands (see УJacking and Vehicle SupportФ). Alternatively, position the car over an inspection pit or on car ramps.

Front pipe
5 Undo the nuts/bolts securing the front pipe flange joint to the manifold, and the single bolt securing the front pipe to its mounting bracket. Separate the flange joint and collect the gasket or spring cup and springs.

6 Slacken and remove the nuts from the front pipe rear flange joint, and recover the clamp or spring cups and springs. Withdraw the front pipe from underneath the vehicle, and recover the gasket.

Front pipe extension
7 Undo the nuts from the front pipe rear flange joint, and the clamp bolts from the extension pipe rear joint.

8 Withdraw the extension from under the vehicle and recover the gaskets.

Intermediate pipe
9 Undo the clamp bolts at each end of the intermediate pipe, then remove the pipe from under the vehicle.

Centre silencer
10 Slacken the clamping ring bolts and disengage the clamps from the front and rear flange joints.

11 Unhook the centre silencer from its mounting rubber and remove it from underneath the vehicle.

Tailpipe and silencer
12 Slacken the tailpipe clamping ring bolts and disengage the clamp from the flange joint.

13 Unhook the tailpipe from its mounting rubbers and remove it from the vehicle.

Complete system
14 Undo the nuts securing the front pipe flange joint to the manifold, and the single bolt securing the front pipe to its mounting bracket. Separate the flange joint and collect the gasket. Free the system from all its mounting rubbers and lower it from under the vehicle.

Heat shield(s)
15 The heat shields are secured to the underside of the body (and on some models to the fuel tank) by various nuts and bolts (see illustration).

16.15 Heat shield on the underside of the fuel tank
16.15 Heat shield on the underside of the fuel tank

Each shield can be
removed once the relevant exhaust section has been removed. If a shield is being removed to gain access to a component located behind it, it may prove sufficient in some cases to remove the retaining nuts and/or bolts, and simply lower the shield, without disturbing the exhaust system.

Refitting
16 Each section is refitted by reversing the removal sequence, noting the following: a) Ensure that all traces of corrosion have been removed from the flanges and renew all necessary gaskets.

b) Inspect the rubber mountings for signs of damage or deterioration, and renew as necessary.

c) Prior to assembling the spring-loaded joint, a smear of high-temperature grease should be applied to the joint mating surfaces.

d) Where joints are secured together by a clamping ring, apply a smear of exhaust system jointing paste to the flange joint, to ensure a gas-tight seal. Tighten the clamping ring nuts evenly and progressively to the specified torque setting, so that the clearance between the clamp halves remains equal on either side.

e) Prior to tightening the exhaust system fasteners, ensure that all rubber mountings are correctly located, and that there is adequate clearance between the exhaust system and vehicle underbody.

Move the system side-to-side, and upand- down, to ensure it will not hit anything when the car is moving.


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